Notes and CautionsThe instructions use two types of service notes:“NOTE”: Provides additional instructions or procedures to com-plete tasks and make sure the equipment functions properly.

Indicates a hazardous situation or unsafe practice that, if not avoided, could result in equipment damage and serious injury.

LocationMount the compressor in a flat, secure location away from heat sources and protected from the elements. The location should provide enough air flow to cool the compressor.Supply at least two holes when mounting the com-pressor inside an enclosure. One hole in the side fac-ing the vehicle front and one hole in the rear-facing side should provide enough air flow from vehicle movement to cool the compressor. Make sure the air line run lengths provide enough slack to allow for vehicle movement. Use a cutting tool instead of a knife or scissors for a clean, straight cut.

Exhaust all pressure from the air system and wear proper eye protection at all times when working on a vehicle air system. Never touch the air compressor or connected fittings with bare hands during or immediately after use. If necessary, wear heat resistant gloves to handle the fittings, air lines, and leader hose.

9710010-D-AirCompressor-MTG-Guide-07-24-20

WiringElectrical wiring should be sized according to the volt-age; the maximum amperage draw of the system compo-nents; and the total wire length. There are several wire gauge calculators online that can help determine the appropriate wire size.The installer is responsible for making sure air system requirements comply with all federal and state regula-tions such as “Federal Motor Vehicle Safety Standards (FMVSS) 121 for Air Brake Systems.” Install near the batteryLocate the air compressor close to the battery to reduce the length of positive lead wire required. Install a larger gauge positive lead wire all the way through the run when mounting the compressor away from the battery - inside the vehicle, for example.Refer to manufacturer’s specifications for the proper fuse size. Locate the fuse as close as possible to power source. Plumb the systemConnections must be airtight to get the proper system performance. Use liquid thread sealant on all threaded air fittings. Torque fittings to 10-12 ft lbs. Mount and plumb remote inlet air filters, if used, in a clean and dry location away from water sources. Replace the filter media when dirty. The air tank drain should point down when mounted. The air line from the air compressor to the air tank should slope downward so that water condensation col-lects in the tank. Drain air tank(s) daily. NOTE: Kinks in air lines or an upward-running air line can cause water to pool/freeze inside the lines. Test for leaksConnect and test the system by running the air compres-sor to build up pressure in the air tank. The compressor will stop when the pressure reaches the “cut-out” pres-sure of the pressure switch. NOTE:Air-ride suspension system air compressors are controlled/limited by a pressure switch. The switch monitors the air tank pressure between a preset maxi-mum and minimum. The air compressor turns off when the pressure reaches the “cut-out level” (120-130 PSI). The compressor turns on when the air tank pressure drops to the “cut-in level” (90-100 PSI).Inspect all air line connections for leaks with soap and water solution. An air line that is not cut squarely or not pushed all the way into the fitting are the most common causes of leaks. Fix or replace as needed.

Air Compressor Kit – Vehicle Mounting Guide

Pressure Check-Valve(One-Way)

Pressure Switch with Relay(Installation after check-valve shown)

Remote Mount Air Filter(as needed)

Drain Valve

3/8” NPT Port

Leader Hose(Air Compressor)

3/8” NPT Port

Air Flow

Typical 12-volt single air compressor/ single air tank configuration. NOTE: Air compressor systems configured for air springs are not to be used with air brakes.

Air Compressor

12-Volt DC

Fuse

Toggle Switch

Black

Big Red

Little Red

Pressure Switch/Relay

Contact (N.O.)

WhiteRelay Coil

P-Switch

M

Pressure Switch/Relay

To Air Filter

To GroundToggle Switch

Hot (Red) wire from power source

Use wire nut to connect two red wires from Pressure Switch to wire coming from toggle switch.(Fasten wires to wire nut with electrical tape)

White

Black WireRed Wires

A/CPSR

12V 30A ATC Inline Fuse(Customer Furnished)

Red

Air Compressor – Wire Diagram

Air Compressor/Air Control Kit Installation and Service Manual

Preventive MaintenanceDrain the moisture from all air reservoirs during each pre-trip/safety inspection. • Compressor power switch should be turned OFF

when trailer is not in use to avoid damage to the vehicle air system.

• Check battery(ies) on a regular basis. The battery should remain at full charge (12.6 volts) at all times.

• Periodically check all electrical and air-fitting con-nections. Clean and tighten as needed.

• Replace air filter element at least once per year. Replace at least once a month if used frequently in a dusty environment.

• Regularly clean dust/dirt from cooling fins and mo-tor housing.

• Check all compressor/accessory mounting bolts. Tighten as needed.

Refer to these American Trucking Association’s Technology & Maintenance Council (TMC) publications on air system maintenance:

RP 617-Air-System Contaminant EliminationRP 619-Air-System Inspection ProcedureRP 634-Ride Height Adjustment Procedures for

Truck/Tractor Air Ride SuspensionsRP 643-Air-Ride Maintenance Guidelines

Height Control Valve (HCV)

Universal Mounting Bracket

Vertical Link

Lever

Lower Mounting Bracket (Tab)(Customer-Furnished)

Axle

90º(Optimal)

45º MAX20º MIN

45º MAX20º MIN

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The Height Control Valve (HCV) automatically adds and exhausts air from the vehicle air system to maintain the proper ride height as loads increase and decrease. A height control kit (HCK) assembly is a lever arm connected to the HCV and a vertical rod arm (vertical linkage) that is connected to the suspension/axle. Refer to the HCV installation guide for installation procedures. Check the air system after installation for leakage.

The installer is responsible for making sure the air system complies with federal and state requirements such as the “Federal Motor Vehicle Safety Standards (FMVSS) 121 for Air Brake Systems.”

Troubleshooting - Air Compressor OperationProblem Possible Cause Corrective Action

Compressor will not operate

— Power switch in OFF position or no power to the switch.

— Inadequate grounding.

— Motor overheated.

— Air tank pressure above the cut-in pressure point.

— Make sure battery is fully charged and compressor switch is turned to ON. Disconnect compressor from power source, check for blown fuse. Replace fuse, if necessary, and reconnect. Refer to Manufacturer Specs for fuse amperage. Use ohm-meter to check the continuity between power source and switch and from power switch to compressor. — Check battery/CPSR grounding with voltmeter. — Let compressor cool approximately 30 minutes to allow thermal overload switch to reset. — Release air pressure until compressor starts.

Fuses burn out repeatedly

— Wrong fuse size. — Electrical short to ground.

— Confirm fuses are proper ampere rating. — Make sure battery/CPSR are properly grounded.

Reset mechanism cuts out repeatedly; properly sized fuses burn out.

— Malfunction/improperly adjusted. — Lack of proper ventilation or temperature around compressor is too high.

— Adjust; repair; or replace compressor.

— Move compressor to well-ventilated area or area surrounded by lower temperature. Add vents to air compressor enclosure, if used.

Compressor runs continuously

— Leak in air system beyond standards.

— Compressor does not stop running (unload) at cut-off pressure point.

— Check-valve stuck in closed position (pressure switch installed after check-valve). — Water in air tank.

— Pressurize system and spray soapy water solution onto the connections. Check for air bubbles (leaks). Re-cut/reassemble lines and tighten connections, as necessary. — Verify air tank pressure. Check that preset cut-off pressure point has been reached (± 5 PSI). Check pressure switch connections. Repair/replace pressure switch, as necessary. — Drain tank and inspect check-valve. Clean/replace faulty parts.

— Drain tank.

Air flow lower than normal

— Clogged air filter element. — Low voltage

— Replace filter element. — Verify system voltage with voltmeter.

Tank pressure drops after air compressor shuts off

— Leak in air system beyond the accepted standards. — Pressure check-valve leaking.

— Water in air tank.

— Check drain valve and tighten. Spray soapy water solution onto system. Check and repair leaks, as needed. — Bleed tank and disassemble check-valve assembly. Clean or replace faulty parts. — Drain tank.

Troubleshooting – Height Control Valve InstallationA “bad HCV” is a common misdiagnosis of the air system not working. Most problems are traced to other parts of the system such as pinched/damaged lines, other valves or loose component fittings. Repair problems before resuming troubleshooting.

Problem Possible Cause Corrective ActionHCV is not receiving air/HCV is not delivering air to the air springs.

—Blocked air supply line.

—Air tank is not filling/reaching set pressure. —Pressure Protection Valve (PPV) not working correctly. —Pilot port is not plumbed or is plumbed incorrectly.

— Verify air lines are pressurized by removing supply line at HCV. Check for pinched lines. — Verify tank pressure with manual/in-line pressure gauge. — Check PPV operation by making sure that valve opens when system reaches the desired pressure setpoint (usually greater than 70 psi). — Check configuration – Non-Dump; Pressure-Dump (Normally Open); Zero-Pressure Dump (Normally Closed). Reinstall, if necessary.

Air springs fill but do not exhaust.

—Obstructed air line.

—HCV installed backwards. —Supply line installed in SUSP port

— Disconnect linkage. Rotate actuating lever to down position (exhaust). If springs remain inflated, check for pinched/blocked lines. — Check installation. Reinstall, if necessary. — Move air supply line to HCV supply port.

Air system leaks down in a short period of time.

—HCV installed backwards.

—Leak in air system beyond the accepted standards.

— Disconnect HCV linkage. Rotate actuating lever to the up position (fill). If air springs do not inflate, reinstall HCV. — To find leak in the HCV area, pressurize system and spray soapy water solution onto the valve and lines. Check for bubbles (leaks): No leak found – Do not remove valve, check the rest of the system for leaks. Check that tubing cuts are straight and smooth. Re-cut and reassemble if necessary.

1/4” Flanged Nut(Torque to 60-80 in-lbs)

1/4” T-Bolt

Supply Port

5/16” or 1/4” Flanged Nuts(Torque to 90-120 in-lbs)

Exhaust Valve

Lower Pin“P”-Connector

Clamp

Upper Pin

1/4” Flanged Nut(Torque to 60-80 in-lbs)

Drive Cap

Grommet

Lever Self-Tapping Screw(Torque to 50-55 in-lbs)

Suspension Port

Alignment Notch

VerticalLink

Height control kit should be installed with the HCV-to-lever angles between 20o-45o to provide maximum flow rates during jounce/rebound travel.

(Non-Dump HCV Shown) Drawing #63300AAAA00 indicates various height control kit (HCK) components for suspensions.